John Deere POWERTECH 4.5 L & 6.8 L Diesel Engines (4045 / 6068) Engine

⚠ Do not manually bottom the valve with excessive force; bending of the valve may result.

Tools: JDG949 Nozzle Wrench, JDG1515-2 Pressure Adjustment Screw Lock Nut Tool, JDG1522 Pressure Adjustment Screw Tool, JDG1521 Spring Chamber Cap Wrench

1. Remove nozzle from tester and install in holding fixture.
2. Remove lift adjusting lock nut.
3. Loosen pressure adjusting screw lock nut using JDG949 Nozzle Wrench.
4. Reconnect nozzle to tester with tip pointing downward.
5. Back out lift adjusting screw two or three turns to prevent bottoming.
6. Turn pressure adjusting screw in (clockwise) to increase opening pressure or out to decrease.
7. Remove nozzle and secure in holding fixture; tighten pressure adjusting screw lock nut to 10 N•m (7 lb-ft).
8. Adjust valve lift: turn lift adjusting screw in until valve ceases to open (conventional nozzle).
9. Turn lift adjusting screw out 3/4 turn counterclockwise (based on zero lift); 1/8 turn tolerance permissible.
10. Tighten lift adjusting screw lock nut to 5 N•m (3.5 lb-ft).
11. Recheck nozzle opening pressure and chatter.

⚠ Stop engine prior to making timing adjustments; injection pump can seize if adjustment is made with engine running.

Tools: JT07158 (FKM10429A) TIME TRAC Kit, JT07177 Clamp-On Transducer, JT07172 Transducer Cable, JDG793 or JDG821 Magnetic Pick-Up Adapter, JDE81-4 or JDG1571 Timing Pin

1. Install JT07158 (or FKM10429A) TIME TRAC Kit.
2. Install transducer or in-line SOI sensor on No. 1 fuel injection line at nozzle end; use No. 4 or No. 6 line if access restricted.
3. Install magnetic pick-up in flywheel timing hole with 0.64 mm (0.025 in.) air gap; do not stop engine at TDC.
4. Engine OFF; push ON/CLEAR; select MAG PROBE, set Trig Level to 70%, press ENTER.
5. Set Offset to 0 degrees and press ENTER.
6. Start engine, press ENTER; run engine at 1300 rpm, press ENTER to calibrate.
7. Warm engine to normal operating temperature; check slow and fast idle rpm; adjust as necessary.
8. Run engine at wide open throttle and load engine down gradually to rated speed rpm.
9. Record engine speed and timing degrees; compare to Section 06, Group 210 or machine technical manual.
10. Stop engine; loosen injection pump mounting flange nuts and adjust pump timing.
11. To advance timing rotate top of pump clockwise (viewed from rear/flywheel end); to retard rotate counterclockwise.
12. Tighten injection pump mounting flange nuts to 27 N•m (20 lb-ft).
13. Start engine and recheck dynamic timing; adjust as needed.
14. Grind away original front plate timing mark and stamp a new mark aligned with injection pump flange mark.

⚠ ALWAYS STOP ENGINE before making adjustments.

⚠ Bumper spring screw should not be used by itself to change engine speed more than 50 rpm.

Tools: Tachometer

1. With engine running, pull governor control lever rearward to slow idle speed position; check speed.
2. Remove slow idle stop screw cover.
3. Loosen lock nut and back out bumper spring adjusting screw three turns.
4. Loosen lock nut and adjust slow idle stop screw to obtain idle 30—50 rpm less than desired slow idle setting.
5. Turn bumper spring adjusting screw in to increase engine speed a maximum of 30—50 rpm to desired slow idle.
6. If surging persists, replace bumper spring and adjustment screw.
7. Recheck fast and slow idle speeds; readjust slow idle if needed.
8. Check all adjusting screw lock nuts for tightness; install covers.
9. Connect fuel shut-off cable and speed control rod.

⚠ After checks are completed, return cold start circuits to original configuration to ensure proper injection pump timing and conformance to emission control standards.

Tools: JT07158 (FKM10429A) TIME TRAC Kit, Jumper wire

1. Install JT07158 (FKM10429A) TIME TRAC Kit; checks must be performed on a cold engine.
2. Verify voltage potential (12 or 24 volts) to the cold start solenoid.
3. Disconnect wiring connector from the cold start advance solenoid.
4. Start cold engine and run at 1200 rpm; check and record injection pump timing.
5. Connect wiring connector to cold start advance solenoid.
6. After approximately 30 seconds, check injection pump timing.
7. Stanadyne: there should be a 7—10° increase in timing; Delphi/Lucas: a 7—10° decrease.
8. If no change, service the cold start advance solenoid and valve, or have the injection pump serviced by an authorized ADS Diesel Repair Station.

⚠ The nozzle tip should always be directed away from the operator; enclose nozzle in a clear glass beaker.

Tools: D01110AA Fuel Injection Nozzle Tester Adapter Set, D01109AA OTC Portable Nozzle Tester, JT25510 Bosch Bench Mounted Nozzle Tester, KJD10109 Fuel Line

1. Connect injection nozzle to nozzle tester.
2. Position tip of nozzle below top of beaker and back out 30 degrees from vertical.
3. Pump handle several strokes to flush air and determine pumping rate required for atomization.
4. Opening pressure test: actuate tester rapidly several times to seat valve.
5. Raise pressure until gauge needle falls rapidly; record nozzle opening pressure.
6. Compare readings to nozzle opening pressure specifications for new or used nozzle.
7. Chatter test: close gauge shut-off valve and operate tester at a rate that causes nozzle to chatter.
8. Operate tester for ten strokes; nozzle must atomize on at least eight strokes without consecutive misses.
9. Spray pattern test: observe pattern and check for plugged, chipped, or eroded orifices.
10. Leakage test: position nozzle tip down, seat valve rapidly, wipe tip dry, raise pressure below opening pressure and hold.
11. If fuel drips from nozzle within 5 seconds, nozzle must be lapped.

⚠ Do not operate engine at high speeds or full loads before bleeding the fuel system.

Tools: Two open-end wrenches

1. Loosen the air bleed vent screw two full turns by hand on fuel filter base.
2. Operate supply pump primer lever until fuel flow is free from air bubbles.
3. Tighten bleed plug securely; continue operating hand primer until pumping action is not felt.
4. Push hand primer inward (toward engine) as far as it will go.
5. Start engine and check for leaks.
6. Stanadyne rotary pumps: slightly loosen fuel return line connector at injection pump.
7. Operate primer lever until fuel without air bubbles flows from return line connection; tighten connector to 27 N•m (20 lb-ft).
8. Delphi/Lucas rotary pumps: loosen bleed screw on pump cover; operate primer lever or turn ignition ON until fuel flows free of bubbles; tighten bleed screw.
9. Denso/Motorpal in-line pumps: open fuel filter port plug; operate hand primer until bubble-free fuel flows; close plug while stroking primer down.
10. If needed, bleed at injection nozzles: move speed control lever to half throttle.
11. Using two open-end wrenches, loosen fuel line connection at injection nozzle.
12. Crank engine with starter motor (do not start) until bubble-free fuel flows out of loosened connection.
13. Tighten connection to 27 N•m (20 lb-ft); repeat for remaining nozzles.

⚠ Contaminated fuel can cause premature failure of fuel injection pump.

1. Thoroughly clean fuel filter/water separator assembly and surrounding area.
2. Connect a drain line to filter drain adapters and drain all fuel from filters.
3. Grasp retaining ring, rotate counterclockwise 1/4 turn (viewed from top), remove ring with filter element.
4. Inspect filter mounting base for cleanliness; clean as required.
5. Remove sediment bowl, if equipped; drain and clean; dry with compressed air.
6. Install sediment bowl onto new filter element; tighten securely.
7. Inspect filter base seal ring; replace as needed.
8. Install new filter element onto mounting base, indexing properly with a slight rocking motion.
9. Install retaining ring and tighten about 1/3 turn until ring snaps into the detent. Do not overtighten.
10. Bleed the fuel system.

⚠ DO NOT move delivery valve fittings while tightening line nuts.

Tools: JDE81-4 or JDG1571 Timing Pin, JDG886 Injection Pump Timing Pin, T45 TORX Adapter

1. Rotate flywheel in direction of normal engine rotation until JDE81-4 or JDG1571 Timing Pin enters flywheel at No. 1 TDC compression stroke.
2. Rotate injection pump drive hub until marks on drive hub and pointer are aligned.
3. Thread JDG886 Timing Pin into drive hub and tighten until it bottoms with the pin located in hole of pointer.
4. Install a new O-ring on bearing plate; lightly lubricate with AR54749 Soap Lubricant.
5. Install injection pump with moderate forward pressure and slight rocking motion; flange should seat solidly.
6. Install mounting stud nuts and tighten to 70 N•m (52 lb-ft).
7. Carefully install drive gear on pump drive hub with cap screws approximately centered in mounting slots.
8. Install drive gear-to-pump hub cap screws and tighten to 47 N•m (35 lb-ft).
9. Remove JDG886 Injection Pump Timing Pin from injection pump hub.
10. Install injection pump drive gear cover using new O-ring; tighten cap screws to 6 N•m (4.5 lb-ft).
11. Connect fuel delivery lines and tighten line nuts to 27 N•m (20 lb-ft).
12. Connect aneroid line, fuel supply pump lines, fuel inlet line and leak-off line.
13. Remove oil fill plug from governor housing and add 3/4 pint of clean engine oil.
14. Bleed fuel system; connect throttle levers and adjust engine speeds as required.

⚠ Do not tighten hex nuts more than three full turns on mounting studs.

⚠ Do not use tightening force of pump mounting stud nuts to pull pump shaft into drive gear ID.

Tools: Torque wrench, 17 mm deep-well socket

1. Lubricate a new square sealing ring with clean engine oil and install into groove on front face of pump mounting flange.
2. Slide injection pump onto mounting studs while inserting pump shaft into drive gear.
3. Check pump shaft and index pin for proper alignment with pump drive gear key slot.
4. Install three flat washers, lock washers and hex nuts; tighten nuts three turns only.
5. Install pump mounting flange flush to engine front plate with drive gear held flush.
6. Finger tighten mounting stud nuts with pump shaft index pin engaged in drive gear key slot.
7. Push pump drive gear firmly onto shaft taper; install washer and retaining nut.
8. Tighten retaining nut: DB2 125 N•m (92 lb-ft); DB4 200 N•m (148 lb-ft).
9. Install access cover plate using a new O-ring; apply LOCTITE 242 to cap screw threads; tighten to 6 N•m (4.5 lb-ft).
10. Align timing mark on pump flange with timing mark on front plate.
11. Tighten three hex nuts securing the pump to the front plate to 27 N•m (20 lb-ft).
12. Connect injection pump pressure lines in firing order (1-5-3-6-2-4 on 6-cylinder; 1-3-4-2 on 4-cylinder); tighten to 27 N•m (20 lb-ft).
13. Connect fuel supply line and fuel return line.
14. Bleed air from fuel system; start engine, run several minutes and check entire fuel system for leaks.

⚠ Once JDG886 Timing Pin is installed, DO NOT turn engine or pump may be damaged.

⚠ Never steam clean or pour cold water on an injection pump while pump is running or warm.

Tools: JDG820, JDE81-1 or JDE83 Flywheel Turning Tool, JDE81-4 or JDG1571 Timing Pin, JDG886 Injection Pump Timing Pin

1. Clean injection lines and area around the injection pump with cleaning solvent or a steam cleaner.
2. Rotate engine flywheel (normal running direction) until No. 1 piston is at TDC of compression stroke.
3. Remove injection pump drive gear cover and O-ring.
4. Install JDG886 Injection Pump Timing Pin through drive gear into pump hub until it bottoms.
5. Disconnect injection pump lube line.
6. Disconnect fuel shut-off solenoid electrical connector.
7. Remove fuel inlet line and fuel leak-off line.
8. Disconnect fuel supply pump lines.
9. Disconnect aneroid line.
10. Remove fuel injection line nuts.
11. Remove four injection pump drive gear cap screws.
12. Remove four mounting stud nuts securing injection pump to cylinder block.
13. Carefully remove injection pump from mounting studs and place on a clean flat surface.

⚠ Never steam clean or pour cold water on a fuel injection pump while the pump is running or while it is warm.

Tools: JDG1560 Injection Pump Drive Gear Puller, 17 mm deep-well crowsfoot socket

1. Clean the fuel injection pump, lines and area around the pump with cleaning solvent or a steam cleaner.
2. Disconnect shut-off cable, speed control linkage and electrical connections; tag wires.
3. Disconnect fuel return line and fuel supply line.
4. Disconnect all fuel delivery (pressure) lines using a 17 mm deep-well crowsfoot socket.
5. Remove injection pump drive gear cover.
6. Remove drive gear retaining nut and washer from end of pump shaft; do not let washer fall inside timing gear cover.
7. Attach JDG1560 Drive Gear Puller to injection pump drive gear.
8. Evenly tighten two 6 mm Grade 12.9 cap screws and snugly tighten center forcing screw against end of pump shaft.
9. Tighten center forcing screw until pump drive gear is free from the tapered shaft; remove puller.
10. Check timing marks on back side of front plate and pump flange are present and aligned.
11. Remove three injection pump mounting stud nuts and remove injection pump.

1. Disconnect electrical wiring connector on solenoid lead.
2. Remove actuator rod cap screw and nut.
3. Remove four cap screws and fuel shut-off solenoid assembly from mounting bracket.
4. Check that fuel shut-off solenoid linkage moves freely back and forth.
5. To install, reverse removal procedure and tighten cap screw to 15—20 N•m (11—15 lb-ft).
6. Connect electrical wiring connector.